Jeep Wrangler TJ. Manual — part 231
AXLE BEARINGS
REMOVAL
(1) Remove axle shaft.
(2) Remove axle shaft seal from axle shaft tube
with a small pry bar.
(3) Remove axle shaft bearing from the axle tube
with Bearing Removal Tool Set 6310 and Adapter
Foot 6310-5 (Fig. 27).
INSTALLATION
(1) Wipe axle shaft tube bore clean.
(2) Install axle shaft bearing with Installer 6436
and Handle C-4171.
NOTE: Part number on the bearing must be against
the installer.
(3) Install new axle shaft seal with Installer 6437
and Handle C-4171 (Fig. 28).
(4) Install axle shaft.
PINION SEAL
REMOVAL
(1) With vehicle in neutral, position vehicle on hoist.
(2) Remove brake drums.
(3) Remove propeller shaft from the yoke.
(4) Rotate pinion gear three or four times.
(5) Record torque necessary to rotate the pinion
gear with an inch pound dial-type torque wrench.
(6) Hold the yoke with Wrench 6958 and remove
pinion nut and washer.
(7) Remove pinion yoke with Remover C-452 and
Wrench C-3281 (Fig. 29).
(8) Remove pinion seal with a pry tool or slide
hammer mounted screw.
Fig. 27 AXLE SHAFT BEARING TOOLS
1 - AXLE SHAFT TUBE
2 - NUT
3 - GUIDE PLATE
4 - GUIDE
5 - THREADED ROD
6 - ADAPTER
7 - FOOT
Fig. 28 AXLE SHAFT SEAL INSTALLER
1 - INSTALLER
2 - SEAL
3 - AXLE SHAFT TUBE
4 - HANDLE
Fig. 29 PINION YOKE REMOVER
1 - WRENCH
2 - YOKE
3 - REMOVER
TJ
REAR AXLE - 194RBI
3 - 101
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal and install seal with an appropriate
installer (Fig. 30).
(2) Install pinion yoke Screw 8112, Cup 8109 and
Spanner Wrench 6958 (Fig. 31).
CAUTION: Do not exceed the minimum tightening
torque 271 N·m (200 ft. lbs.) when installing the pin-
ion yoke at this point. Failure to heed caution may
result in damage.
(3) Install yoke washer and new nut on pinion
gear and tighten nut until there is zero bearing end-
play.
(4) Tighten pinion nut to 271 N·m (200 ft. lbs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion gear bearing rotating torque and never
exceed specified preload torque. Failure to heed
caution may result in damage.
(5) Rotate pinion shaft using an inch pound torque
wrench. Rotating torque should be equal to the read-
ing recorded during removal plus an additional 0.56
N·m (5 in. lbs.) (Fig. 32).
Fig. 30 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 31 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 32 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
3 - 102
REAR AXLE - 194RBI
TJ
PINION SEAL (Continued)
(6) If rotating torque is low, use Wrench 6958 to
hold pinion yoke (Fig. 33), and tighten pinion nut in
6.8 N·m (5 ft. lbs.) increments until proper rotating
torque is achieved.
CAUTION: If maximum tightening torque 475 N·m
(350 ft. lbs.) is reached prior to reaching the
required rotating torque, the collapsible spacer may
have been damaged. Failure to heed caution may
result in damage.
(7) Install propeller shaft.
(8) Install the brake drums.
COLLAPSIBLE SPACER
REMOVAL
(1) With vehicle in neutral, position vehicle on
hoist.
(2) Remove rear brake drums.
(3) Remove propeller shaft.
(4) Rotate pinion gear three or four times.
(5) Record torque to rotate the pinion gear with an
inch pound dial-type torque wrench.
(6) Hold pinion yoke with Spanner Wrench 6958
and remove pinion nut and washer.
(7) Remove pinion yoke with Remover C-452 and
Flange Wrench C-3281 (Fig. 34).
(8) Remove pinion shaft seal with a pry tool or a
slide hammer mounted screw.
(9) Remove front pinion bearing using a pair of
pick tools to pull the bearing straight off the pinion
gear shaft.
NOTE: If bearing becomes bound on pinion shaft,
lightly tap the pinion shaft with a rawhide/rubber
hammer.
(10) Remove collapsible spacer.
INSTALLATION
(1) Install a new collapsible preload spacer on pin-
ion shaft.
(2) Install pinion front bearing.
(3) Apply a light coating of gear lubricant on the
lip of pinion seal and install seal with an appropriate
installer (Fig. 35).
Fig. 33 YOKE HOLDER
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
Fig. 34 PINION YOKE REMOVER
1 - WRENCH
2 - YOKE
3 - REMOVER
Fig. 35 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
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REAR AXLE - 194RBI
3 - 103
PINION SEAL (Continued)
(4) Install yoke with Screw 8112, Cup 8109 and
Spanner Wrench 6958 (Fig. 36).
(5) Install yoke washer and new nut on the pinion
gear. Tighten the nut to 271 N·m (200 ft. lbs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion gear bearing rotating torque and never
exceed specified preload torque. Failure to heed
caution may result in damage.
(6) Using yoke with Spanner Wrench 6958 and a
torque wrench set at 475 N·m (350 ft. lbs.), (Fig. 37)
slowly tighten the nut in 6.8 N·m (5 ft. lbs.) incre-
ments until the rotating torque is achieved. Measure
rotating torque frequently to avoid over crushing the
collapsible spacer (Fig. 38).
CAUTION: If more than 475 N·m (350 ft. lbs.) torque
is required to crush the collapsible spacer, the
spacer is defective and must be replaced. Failure to
heed caution may result in damage.
(7) Check rotating torque with an inch pound
torque wrench (Fig. 38). The rotating torque of the
pinion
should
be,
the
reading
recorded
during
removal plus an additional 0.56 N·m (5 in. lbs.).
(8) Install propeller shaft.
(9) Install rear brake drums.
Fig. 36 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - SPANNER WRENCH
Fig. 37 YOKE HOLDER
1 - PINION YOKE
2 - SPANNER WRENCH
3 - PIPE
Fig. 38 PINION ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
3 - 104
REAR AXLE - 194RBI
TJ
COLLAPSIBLE SPACER (Continued)
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